Warrior Products 30840 Installation guide

Brand
Warrior Products
Model
30840
Category
Motor vehicle electronics
Type
Installation guide
INSTALLATION INSTRUCTIONS
Page 1
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ure 1
30840 TJ 4” LIFT KIT
Warrior recommends installation of this kit by a certified technician. In addition to these instructions, professional knowledge
of disassemble/re-assembly procedures, as well as post installation checks must be known. Attempts to install this system
without this knowledge and expertise may jeopardize the integrity and/or operating safety of the vehicle.
Please read instructions before beginning installation. Check the kit hardware against the parts list. Be sure you have all
needed parts and know where they go.
With the installation of all lift kits and larger tires it is important to check the condition of
your steering stabilizer. If the stabilizer is worn or is leaking it should be replaced. A
multiple stabilizer kit is recommended for vehicles equipped with a snow plow, winch, or
larger tires.
Please read instructions before beginning installation. Check the kit hardware against the
parts layout and list found on the last page of these instructions. Be sure you have all
needed parts and know where they go.
With the installation of all lift kits and larger tires it is important to check the condition of
your steering stabilizer. If the stabilizer is worn or is leaking it should be replaced.
Steering stabilizers are designed to restrain “bump steering” and front end vibration, giving added life to tires,
ball joints, and other steering components. A multiple stabilizer kit is recommended for vehicles equipped with a winch or
larger tires
PRODUCT USE INFORMATION
1. As a general rule, the taller a vehicle is, the easier it will roll. Offset, as much as possible, what is lost in rollover resistance
by increasing tire track width. In other words, go "wide" as you go "tall". Many sportsmen remove their mud tires after
hunting season and install ones more appropriate for street driving; always use as wide a tire and wheel combination as
possible to enhance vehicle stability.
2. We strongly recommend, because of rollover possibility, that the vehicle be equipped with a functional roll-bar and cage
system. Seat belts and shoulder harnesses should be worn at all times. Avoid situations where a side rollover may occur
3. Generally, braking performance and capability are decreased when significantly larger/heavier tires and wheels are used.
Take this into consideration while driving.
4. Do not add, alter, or fabricate any factory or after-market parts to increase vehicle height over the intended height of the
Warrior product purchased. Mixing component brands is not recommended.
5. Warrior makes no claims regarding lifting devices and excludes any and all implied claims. We will not be responsible for
any product that is altered.
6. The required installation time for this system is approximately 8 hours.
7. This suspension system was developed using a 33 x 12.50R – 15 tire, on a 8” wheel. Before installing other combinations,
please consult your local tire and wheel specialist.
8. The following tools and supplies are recommended for proper installation of this kit.
a. Spring Compressor b. Pitman Arm Puller
c. Silicone Spray d. Drill Motor
e. Drill Assortment (1/8” to 1/2") f. Torque Wrench (250 ft lbs. Capacity)
g. Hammer h. ½” Drive Ratchet and Sockets
i. Combination Wrenches j. Allen Wrenches
k. Torq Key Socket l. Hacksaw
m. File n. Large “C” Clamps and/or Bench Vise
o. Hydraulic Floor Jacks p. Heavy Duty Jack Stands
q. Wheel Chocks (Wooden Blocks) r. Molybdenum Grease or Anti Seize Compound
s. Safety Glasses – Wear safety glasses at all times
If question exist we will be happy to answer any questions concerning the design, function, and correct use of our products.
STANDARD BOLT TORQUE SPECIFICATIONS
INCH SYSTEM METRIC SYSTEM
Bolt
Size Grade 5 Grade 8 Bolt Size Class 9.8 Class 10.9 Class 12.9
5/16 15 Ft – Lbs 20 Ft – Lbs M 6 5 Ft – Lbs 9 Ft – Lbs 12 Ft – Lbs
3/8 30 Ft – Lbs 35 Ft – Lbs M 8 18 Ft – Lbs 23 Ft – Lbs 27 Ft – Lbs
7/16 45 Ft – Lbs 60 Ft – Lbs M10 32 Ft – Lbs 45 Ft – Lbs 50 Ft – Lbs
½ 65 Ft – Lbs 90 Ft – Lbs M12 55 Ft – Lbs 75 Ft – Lbs 90 Ft – Lbs
INSTRUCTION SHEET
Technical Assistance - (888) 220-6861 Page 2
Fi
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9/16 95 Ft – Lbs 130 Ft – Lbs M14 85 Ft – Lbs 120 Ft – Lbs 145 Ft – Lbs
5/8 135 Ft – Lbs 175 Ft – Lbs M16 130 Ft – Lbs 165 Ft – Lbs 210 Ft – Lbs
¾ 185 Ft – Lbs 280 Ft – Lbs M18 170 Ft – Lbs 240 Ft – Lbs 290 Ft – Lbs
NOTICE TO DEALER AND VEHICLE OWNER
Any vehicle equipped with any Warrior should have a “Warning to Driver” decal installed on the inside of the windshield or on
the vehicle’s dash. The decal should act as a constant reminder for whoever is operating the vehicle of its unique handling
characteristics.
INSTALLING DEALER - it is your responsibility to install the warning decal and forward these installation instructions on to
the vehicle owner for review. These instructions should be kept in the vehicle for its service
INSTALLATION INSTRUCTIONS
1. Place the vehicle on a level surface. Set the parking brake. Center front wheels and chock rear wheels. From inside the
engine compartment, remove the upper stud nut, retainer and grommet form both of the front shocks Jack up the vehicle
and place jack stands on the frame rail behind the lower control arm mount
on the frame. Installation is done one end at a
2. time. The front-end components are installed first.
3. Remove the front tires and wheels.
4. Place a floor jack underneath the axle for support and complete the removal
of the front shock absorbers (DO NOT REUSE THE ORIGINAL SHOCK
ABSORBERS).
5. Remove the track rod from the axle housing and secure out of the way.
Save the bolt and flag nut they will be reused in a later step. Remove both
of the front sway bar end links.
6. Remove the brake calipers and secure out of the way.
7. Mark the position of the lower control arm cam bolt and axle brackets for
installation reference. (See Figure #1) If equipped with ABS brakes,
Remove the sensor wires and clamps for the inside of the lower arms and
save clamps for re-use.
8. Remove the coil spring clip located on the bottom coil seat on both sides of the vehicle. Lower the axle and remove the
coil spring. A coil spring or strut compressor may be needed to remove the stock coil spring.
9. Remove the stock lower control arm by removing the nut, cam, and cam
bolt from the axle bracket and then removing the nut and bolt from the
frame bracket. Install the new bushings and sleeves in the Warrior, Inc
control arm and install on the vehicle using factory hardware – do not
tighten at this time. Note: The part of the arm with the slight bend in it
will install on the axle mount.
10. If applicable, drill a 23/64” hole into each lower link and reinstall the
ABS sensor wires. Use the original clamps.
11. Install the coil spring. A coil spring or strut compressor will be needed
for the new coil spring installation. Compress the new coil spring to
16” in length. Install the new spring into the upper and lower spring
pockets and carefully remove the compressor. Make sure the coil is
seated properly in the coil seat by rotating the spring so the pig tail end
fits in the spring pocket. Install the coil spring clamp and torque the
spring clip bolt to 16ft.-lbs.
12. Repeat steps on other side.
13. Install the WARRIOR, INC. track rod extension bracket in the factory location as shown in Figure #2. Slide the bracket
all the way up to the flange in the stock bracket. Install the stock bolt in the upper hole and tighten. Using the bracket as a
guide, drill a 3/8” hole and install the new bolt, washers and lock nuts. Install the new 12mm x 65mm bolt, washers and
nut in the track rod on the lower mount and tighten.
14. Assemble the boots on the front shock absorbers and install in the factory lower mounts. Install the upper stud bushings
and tighten the upper mounting point. Tighten the bar pin on the bottom of the shock with the stock hardware. Repeat this
on the opposite side of the vehicle. Install the tires, wheels and lug nuts. Lower the vehicle to the ground.
15. Install the sway bar hoop on the sway bar where the stock link was secured, using the supplied 3/8” x 1.75” bolt, washer
and nylon lock nut. Install the bushings and 12mm sleeves provided in Bag # 2 on the bottom of the link at this time and
use the factory hardware to install. The upper sway bar bushings are in Bag # 3. These are installed on the top of the sway
Figure 2
INSTRUCTION SHEET
Technical Assistance - (888) 220-6861 Page 3
bar link with the 12mm sleeves. These bushings are a little thicker than the lower sway bar bushings. Install the upper part
of the new link in the hoop bracket with the 12mm bolts & hardware See Figure #3.
16. Tighten the lower suspension arm to frame bracket nut and bolt to 130 ft. lbs. (both sides).
17. Align the reference marks on the adjustment cams and lower arm axle
brackets and tighten to 85 ft. lbs.
Note: Longer brake lines are not required in the front with this kit unless the
sway bar is disconnected. If disconnects are used, longer brake lines are
required.
18. Chock the front wheels. Jack up the rear of the vehicle and remove the
tires and wheels. Place jack stands on the frame rail to support the
vehicle. Place a floor jack under the differential. Remove the stock
shock absorbers and sway bar links. Retain the factory shock hardware it
will be reused.
19. On the rear of the vehicle unbolt the track rod from the axle and secure
out of the way.
20. Carefully lower the axle with the floor jack and remove the coil springs.
NOTE: It may be necessary to use a coil spring or strut compressor to remove the stock coil springs. Be careful not
to overextend the vent tube on the axle. It may be necessary to disconnect the hose during installation and reroute the hose
after installation.
21. Disconnect the track bar from the axle bracket and install the new track
bar relocation bracket in the stock location. See Figure #4 and 5. Secure
to the stock location using the 2-5/16” x 1” long bolts, washers and nuts
as shown in the picture. NOTE: It may be necessary to enlarge the
holes at these locations. If this is the case drill these holes to
accommodate the 5/16” bolts. Install the ½” x 1 ½” bolt washers and nut
in the stock track rod bolt location and tighten. Refer to the pictures to the
right. Do not install the track rod in the new bracket at this time.
22. Remove and replace one suspension arm at a time. Remove the lower
arm axle and frame mount bolts. Remove the lower arm. Install new
lower arm to the frame and axle brackets. Use the original hardware but
do not tighten at this time. Then repeat these steps on the other side.
Note: The part of the arm with the slight bend in it will install on the axle
mount
23. Install the new Warrior, Inc coil springs making sure that the rubber
damper is positioned in the upper mount. It will be necessary to use a coil spring or strut compressor to install the new coil
springs. Jack up the axle to compress the coil spring and to align the track rod with the new mounting point and install the
stock mounting hardware. See Figure 4 & 5 above.
24. Assemble shock with the shock bushings and sleeves in the shock bag on
the larger barrel end. Install the shocks on the vehicle with the factory
hardware.
25. Reinstall the wheels, tires. Lower the vehicle to the ground and tighten
the lug nuts to the factory torque specifications (80-110 ft-lbs.)
26. On the rear, assemble the sway bar bushings and 10mm sleeves in the
new rear extended sway bar links. Secure the links to the stock location
using the 10mm x 60mm bolts, washers and nuts supplied. Tighten to 40
ft. lbs. See Figure 6
27. Tighten lower arm pivot bolts to 130 ft. lbs and the track bar mounting
bolts to 74 ft. lbs.
28. A brake line bracket is supplied with this kit for the rear of the vehicle.
Remove the brake line at the frame mount. Do not remove the rubber line
from the steel line. This will cause the brakes not to function properly
unless the lines are bled. Mount the bracket to the factory location with the supplied hardware and tighten. Place the
factory line at the other end of the bracket in the slotted hole.
Figure 5
Fi
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ure 6
Figure 4
INSTRUCTION SHEET
Technical Assistance - (888) 220-6861 Page 4
TRANSFER CASE INSTRTUCTIONS
1. Place the transmission in neutral and place floor jack under the transmission mount skid plate.
2. Using a floor jack, support the skid plate.
3. Slightly loosen the bolts on the transfer case skid plate on both
sides to allow for some movement. Do not remove the bolts.
4. Proceed to other side. NOTE: Do not attempt to take out the
bolts on both sides simultaneously. Installation is done one side
at a time. Remove the three bolts holding the transfer case skid
plate to the frame rail. On some models an additional skid
plate is mounted just forward of the transfer case skid plate.
If equipped with this plate, use the same spacers, supplied
with the kit to lower.
5. Using the floor jack, slightly lower the skid plate and insert the
transfer case lowering spacers as shown below. Please note the
spacers should have the metal sleeve installed in the bushing
to prevent crushing. Secure with the 12 mm bolts and washers
supplied with the kit and slightly tighten. Do not fully tighten to
allow for some movement for the opposite side.
6. Proceed to the opposite side of the vehicle and install the brackets as instructed above. After installing both sides, tighten
bolts to 45ft lbs. PITMAN ARM INSTALLATION
1. Remove the cotter pin and nut from the drag link at the pitman arm. Separate the drag link ball stud from the pitman arm
with a puller tool. Do not use a pickle fork.
2. Center the steering wheel and mark the position of the original pitman arm. Remove the nut and washer from the steering
gear box.
3. Remove the pitman arm from the steering gear with a pitman arm puller.
4. Align and install new pitman arm on the steering gear shaft. Install the washer and nut. Tighten to 185 ft. lbs.
5. Install the drag link ball stud to the pitman arm. Install the nut and tighten to 60 ft lbs. Install a new cotter pin.
FLOOR PAN MODIFICATION (Manual Transmission Only)
1. Move the seats to full rearward positions.
2. Pry up the shift boot and bezel from the floor console.
3. Remove the bolts attaching the console to the floor pan and lift the console upward and remove.
4. Remove the 4 screws attaching the cover boot to the cover and slide the boot upward to expose the opening in the floor
pan.
5. Shift the transmission to 2nd and reverse verifying a minimum of 1/8” clearance between the shifter lever and the floor pan.
If necessary, enlarge the opening in the floor pan with a round file.
6. Reposition the cover boot and install one screw on the left side.
7. Rotate the boot clock wise to match the increased floor pan opening. Mark and drill three new mounting holes.
8. Reinstall the cover boot, console, and shift boot.
POST INSTALLATION INSTRUCTIONS
1. Check all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile, fixed and
heated members. Check steering gear for interference and proper working order. Test brake system.
2. Readjust headlamps. Have the vehicle aligned to the following specifications:
Adjustment Preferred Range
Caster 7° ± 1°
Camber - 0.25° ± .63°
Toe_In (each wheel) 0.15° ± .15°
Thrust Angle 0° ± .15°
3. Perform steering sweep. Check to ensure brake hoses have sufficient slack and will not contact rotating, mobile, or fixed
members, adjust lines/brackets to eliminate interference and maintain proper working order. Failure to perform
inspections may result in component failure.
4. Re torque all fasteners after 500 miles. Visually inspect components and re torque fasteners during routine vehicle service.
MAINTENANCE INFORMATION
INSTRUCTION SHEET
Technical Assistance - (888) 220-6861 Page 5
LOWER CONTROL ARMS
It is the ultimate buyers responsibility to have all bolts/nuts checked for tightness after the first 100 miles and then every
1000 miles. Wheel alignment, steering system, suspension and driveline systems must be inspected by a qualified professional
mechanic at least every 3000 miles. PARTS LAYOUT AND KIT CONTENT
FRONT COIL SPRINGS FRONT SHOCKS
REAR SWAY
BAR LINK
S
REAR
COIL
SPRINGS
FRONT TRACK
BAR BRA
C
KET
TRANSFER CASE
DR
O
P BRA
C
KET
S
REAR SHOCKS
REAR TRACK
ROD
BRACKET
FRONT
SWAY BAR
LINKS AND
HOOP
BRACKETS
REAR
BRAKE
LINE
BRACKET
REAR LWR CTRL ARMS
Front Track Bar Bracket 12 – 1.75 x 65 mm bolts(7) Cont Arm Bushing (16) Stem Bushing (4)
Rear Track Bar Bracket M12 – 1.75 Flange Lock Nuts 3 /4x 5/8” 2.6” Sleeve(8) Cup Washers (4)
Transfer Case Lowering Spacers (2P/D) 3/8”-15x1.25 Bolt G8 (1) 7/16” Washer (12) 3/8” Hex Nut (2)
Pinion Cam Bolts (2 sets) 3/8” Washer (2) Sway Bar Bushing (12) Pal Nut (2)
Front Sway Bar Links (2) 3/8” –16 Top lock nut (1) ES17 Sleeve (4) ES24 Sleeve (2)
Rear Sway Bar Links (2) 5/16”-18 Hex nut (2) ES83 Sleeve (2) Hourglass Bsh (2)
Lower Control Arms (2) 5/16” –18x1” Bolt G8 (1) ES83 Sleeve (2)
Shock Absorbers (4) ¼” Washer (4)
Black Boots (4) ½” –13 x 1.5 Bolt G8 3/8”x1.75 Bolt (2)
Boot Ties (4) ½” Washer (2) 3/8” 24 Nut (2)
Brake Line Bracket ½” – 13 Nut (1) 3/8” Washer (2)
Front Sway Bar Bracket. 5/16” Lock Washer (2)
Pitman Arm 3/8” Flat washer (4)
½” – 13 x 3.5” Bolt G8 (6)
3/8” – 16 nylock nut (2)
Conical Washers (6)
Front Coil Springs Rear Coil Springs
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Warrior Products 30840 Installation guide

Brand
Warrior Products
Model
30840
Category
Motor vehicle electronics
Type
Installation guide
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